JP6781160B2 - Shielded electrical connector - Google Patents

Description

The present invention relates to a shielded electric connector that connects or distributes a shielded electric wire or a plug connector to each other, and a method for manufacturing the shielded electric connector.

Such a shielded electrical connector can have the form of a connection between two coaxial cables, or a connection between a plurality of shielded cables forming a distributor, or this connection can be a shielded cable and a plug. It can be between connectors, or it can take the form of a multi-directional shielded terminal block that connects multiple shielded plug connectors or shielded cables.

German Patent No. 19613228 has a metal coupling device including a union nut or screw and an inward collar that engages the crimp sleeve between the coupling device and the shield of the connecting cable. An electrical connector with a connection cable that forms the connection is described. Manufacturing a shielded plug connector with a crimped shielded sleeve is costly. Many individual parts are required, and the preparation of cables to connect is done manually as with the installation of many individual parts. In the case of a plug connector having an angular shape, it is even more difficult to learn how to manufacture it. Furthermore, establishing an electrical connection with a crimp component is not always safe, specifically, the contact resistance of the crimp connection changes when the temperature changes or over time, and the shield quality of the plug connector deteriorates. There is also.

U.S. Pat. No. 5,906,513 includes a molded shielded electrical connector in which a sleeve-shaped metal housing with slits forming tabs is provided on the side of the cable and the tabs are pressed against the metal braided shield of the cable. Are listed. The sleeve-shaped metal housing is then embedded with a thermoplastic material behind the metal connection coupling, on the exposed metal braided shield, and on the end of the cable. Thermoplastic materials include wire strands that are pressed against a sleeve-shaped metal housing during the molding process to establish good electrical conduction between the cable and the connector or to the sleeve-shaped housing of the plug connector. In this case as well, the contact resistance between the shield parts may deteriorate when the temperature changes and over time.

German Patent No. 102008018403 and International Publication No. 2011/151373 describe a plug connector to which a shielded cable is connected. The connector has a molded shielded sleeve made of a conductive material, specifically a conductive plastic, which electrically connects the shielded portion of the cable to the connecting nut of the plug connector. Generally, a plastic filled with metal fibers is interpreted as a conductive plastic. Such conductive materials can be injection molded (see DIN 24450). More specifically, the wire ends of the cable are connected within the plug housing in which the metal sleeve is located. Then, an insulating carrier extending from the wire shield into the housing is injection molded. A conductive sleeve component is injection molded around the insulating carrier so that it is also connected to the housing shield of the electrical connector by connecting the wire shield to the metal sleeve. However, conductive plastic establishes only weak contact with the metal surface of the plug connector or cable, and thus the contact resistance of the transition surface between the conductive plastic material and the metal surface at the shield of the plug connector or cable. The value of is increased, and therefore, if gaps or cracks are generated due to shrinkage or melting of the plastic, further deterioration may occur. In addition, conductive plastics have the disadvantage of having lower screening damping properties than perfect metals.

German Patent No. 19613228 U.S. Pat. No. 5,906,513 German Patent No. 102008018403 International Publication No. 2011/151373 German Patent No. 10201209790

An object of the present invention is to form a shielded electrical connector with good shielded connections between shielded wires and / or shielded plug connectors.

A further aspect of the invention is to form a durable shielded electrical connector that keeps the contact resistance between the associated shielded components low during the life of the connector.

Another feature of the present invention is to form a shielded electrical connector with as few individual parts as possible, most of which can be easily manufactured automatically.

Means for solving the problems of the present invention are found in the subject matter of the independent claims. The dependent claims define the advantageous improvements of the present invention.

More specifically, the shielded electrical connector has at least one wire or one or more wire elements belonging to at least one plug connector. In the case of multiple wires, these wires can be connected at least partially to each other to form a distributor. The wire element can be formed exemplary as an electrical cable wire or as a continuous plug contact element of a plug connector. The connector further comprises one or more shield sleeves and / or one or more shield housings that belong to at least one wire as a cable shield or to at least one plug connector as a housing shield. The present invention provides a shield housing that connects a plurality of shield sleeves, or connects at least one shield sleeve to at least one shield housing, or connects a plurality of shield housings to each other, or forms a part of the shield housing. Including further. The shield housing is composed of a cast metal body that is cast in situ on the annular region of one or more shield housings as well as the annular region of one or more shield sleeves. The cast metal body is a fixing means with low electrical contact resistance and provides a complete, specifically gap-free shield for the connector. The shielded housing can also extend between two shielded cables or a group of cables that connect to each other.

In other words, the shield housing is not composed of off-the-shelf shell or sleeve parts, but is cast directly and integrally with the connector and its surroundings, specifically the connector's plastic parts and its surroundings, during assembly or manufacturing. It is preferable to be done. Therefore, a liquid metal or a liquid metal alloy is cast in and around the plastic part of the connector. Thus, the shield housing is in-situ cast from liquid metal in an already partially manufactured connector, or in-situ around the parts of a partially manufactured connector.

This avoids the formation of gaps that can occur when crimping the sleeve onto the shield sleeve of the cable, or when the shield contains two crimp sleeves. In addition, there is low contact resistance between the shield housing of the cable's shield sleeve and / or plug connector and the shield housing that is integrally cast from liquid metal and / or connects the shield housings to each other. The electrical connections formed by the integrally cast in-situ shield housing are durable and subject to little aging. Adopting the present invention means that the ready-made shield sleeve that needs to be attached is not used, which further simplifies the manufacture of the connector. In the case of angled connectors, significant simplifications and quality improvements are evident.

Manufacture of shield housings by pouring metal directly into the shield sleeves and / or shield housings has established the result of better fixation between adjacent shielded parts and stronger connections, contact between shield components. The resistance is low. Metallurgical connections can also occur if the materials of the parts that connect to each other are properly selected. Such connections are particularly durable and consistent in quality.

According to embodiments of the present invention, the shield housing is at least partially cast on and around an intermediate insulation portion made of a heat resistant electrically insulating material. The intermediate insulation protects the wire element during casting of the shield housing. When handling the wire element during assembly of the connector, the shield sleeve, usually composed of a metal braid, is stripped from the end of the wire element, such as the insulating wire of a cable. Even if the wire element is covered by wire insulation, it may be advantageous to use additional intermediate insulation to better protect the wire element from the hot molten metal stream when casting the shield housing. The intermediate insulation is made of a heat resistant electrically insulating material and can be thick enough to meet the casting requirements of the shield housing.

In the case of a plug connector that is fitted and connected to a mating plug connector, a continuous contact element behind the plug connector is used as a wire element. The contact or wire elements are properly housed by the electrically insulated connector housing. Around the connector housing that holds the contact or wire element, a fitting half of the plug connector designed to cooperate with the other fitting half of the fitted plug connector is assembled. The other joint half body is effective as an electric shield connection. This is a simple and reliable shielded plug connector design.

The shield housing of the plug connector can be a metallic connecting part, including a metal half shell secured onto the insulating connector housing using a coupling ring, forming part of the fitting half of the plug connector. can do. The rear edge of the metallic connector is insert-molded with a shield housing around it so that a good electrical connection corresponding to the degree of shielding performance of the plug connector appears between it and the shield housing of the plug connector. Or it is cast.

If the plug connector is formed for data wires and preferably has multiple wire elements, these elements are protected by an intermediate insulation formed of an electrically insulating low thermal conductive material. The thermal conductivity of the intermediate insulating part material is preferably 0.01 W / m · K-10 W / m · K. Among those to be considered are, for example, polyethylene terephthalate (PET), polyurethane compact (PUR), polyimide (eg Kapton®), polyetherimide (PEI), polytetrafluoroethylene (PTFE), polyvinyl chloride (PVC). ), Polyamide (eg, Nylon® or Perlon®), Polypropylene (PP), Polycarbonate (eg, Makron®), Epoxy Resin, Polymethylmethacrylate (PMMA), Polyethylene (PE), Polystyrene ( PS), polysiloxane (silicon), and polybutylene-terephthalate (PBT). If necessary, the intermediate insulation is made of foamed plastic capable of achieving a thermal conductivity of 0.01 W / m · K to 0.1 W / m · K, preferably about 0.02 W / m · K. .. This provides solid protection for the wire insulation, which is easily scratched during casting of the shield housing.

If one of the wire elements of the plug connector is on the protective ground (PE wire), the shield housing is preferably cast directly on the protective ground and integrally with the casting branch. This connection is an easy and secure connection between the outer shield and the protective ground (PE wire) extending inward, which simplifies the overall structure of the plug connector.

For power plug connectors, the intermediate insulation is made of an electrically insulating material with good thermal conductivity. The shield housing is preferably provided with cooling fins, and more specifically, the shield housing is cast in-situ from metal including the cooling fins on an intermediate insulating portion having good thermal conductivity. In this case, the thermal conductivity of the intermediate insulating material is preferably 0.2 W / m · K-10 W / m · K. Possibly, ready-made intermediate insulation made of LATICONTHE® or ceramic is conceivable. In the case of high load and high heat generation, this power plug connector can effectively dissipate heat in spite of its simple design.

Whether it is a data connector or a power connector, use the intermediate insulation as a ready-made intermediate insulation, or as an in-situ injection molding when using thermoplastics, in the shield housing. It can be executed before casting to enable an efficient production process.

The connector according to the invention can also be formed as a multi-directional terminal block for one or more shielded wires and / or one or more shielded plug connectors. Provided is a multi-directional terminal block or distributor having multiple connection points for conductor elements belonging to either one or more wires or one or more plug connectors. The distributor and adjacent wire elements are protected during the manufacture of the shield housing and during subsequent operation of the device. The shielded housing directly surrounds the intermediate insulation and is cast in-situ, either in the annular region of the shielded sleeve of the shielded wire and / or in the end region of the shielded housing of the plug connector, depending on the connection and distribution partner. , So it is firmly connected. Thus, the structure of this distributor allows for a plurality of different multi-directional terminal blocks or distributors, and one or more plug connector connections, or one or more direct wire connections can also be used in various forms. ..

As is common in the industry, the shield housing is preferably surrounded by a plastic insulating protective shell in order to give the invention a aesthetically pleasing appearance and electrically insulate the shield housing.

The shield housing made of cast metal can be made of, for example, a low melting point metal alloy. In this case, the solidus temperature is 120 ° C to 420 ° C. The metal alloy can be a metal solder such as tin solder in particular. For example, when tin solder (melting temperature of about 230 ° C.) is used, no damage to the molded plastic parts is observed in the wire insulating portion and the intermediate insulating portion. In particular, with the use of metal solder, the shield housing fuses with parts such as the shield sleeve or tin plating of the shield housing during in-situ casting and melts together to establish a particularly low resistance shielded connection.

The present invention also relates to methods of making shielded electrical connectors in its various embodiments.

Therefore, the method for manufacturing the shielded electric connector is generally performed as follows.
a) Connect the free ends of the wire elements to each other.
b) Optional intermediate insulation is applied on the free ends of the line elements connected to each other.
c) The shield housing is formed by casting liquid metal around one or more exposed shield sleeves and / or one or more shield housings and, if necessary, around intermediate insulation.

In this step, the step of applying any intermediate insulation can be performed by in-situ injection molding on the free end of the wire element, depending on the material, or a ready-made intermediate insulation is applied. You can also do it.

If the shielded electrical connector connects two shielded wires to each other, the ends of the two wires on the shielded sleeve and wire element are exposed. The free exposed ends of the wire elements are connected to each other and an intermediate insulation is placed on the free exposed ends of the connected wire elements. After that, the intermediate insulating portion and the exposed shield sleeve are cast and wrapped with liquid metal to form a shield housing. As a result, a connector having a low electrical contact resistance between the shield sleeve of the wires connecting to each other and the shield housing of the connector can be obtained. This low electrical contact resistance promises to remain permanently low even if the connector is handled roughly.

When manufacturing an electric shielded plug connector that connects the wire element of the shielded wire onto the contact element of the connector, the shielded sleeve and the end of the shielded wire of the wire element are exposed. Fix the contact element of the plug connector to the end of the wire element of the shielded wire. Insulate them from each other by inserting the contact elements into the insulating connector housing. Intermediate between the insulated connector housing and where the wire elements are exposed from the common insulating shell, thus by casting a heat resistant plastic material, for example, on the exposed or individually insulated wire elements. Apply insulation. It is preferable to use a plastic having heat resistance in the range of 180 ° C. to 230 ° C. After that, the intermediate insulating part and the shield sleeve with the exposed wire are cast and wrapped with liquid metal to form a shield housing. This produces a plug connector with a simple and robust construction that promises low electrical contact resistance between the shield sleeve of the connected wire and the shield housing of the plug connector and remains low for the life of the plug connector. can do.

If the connector is designed as a multi-directional terminal block, it is necessary to connect the multi-directional terminal block directly with one or more wires, or to provide one or more individual plug connectors in the multi-directional terminal block. Depending on the presence or absence of the shield sleeve and the end of one or more wires connecting the wire elements, and / or providing a plug connector with each shield housing and each wire element. Next, the line element is connected to the distributor. Next, intermediate insulation is applied on the exposed wire element and around the distributor, for example by insert molding with plastic. The shield housing is then formed by casting the intermediate insulation and all exposed shield sleeves and / or, in the case of plug connectors, the edge region of the shield housing with liquid metal. Therefore, the present invention allows the design of various electrically shielded multi-directional terminal blocks.

In the method according to the present invention, the solder connection between the shield housing and the shield sleeve can be made by partially fusing the solder materials in each shield sleeve. Such solder connections are made during casting of metal shield housings and when each shield sleeve is ready, for example when a tin-plated wire mesh is used as the shield sleeve.

Hereinafter, the present invention will be described in more detail with reference to the drawings using embodiments, but in the drawings, the same and similar elements are partially designated by the same reference numerals, and the features of different embodiments are mutually characteristic. It can also be combined.

An exemplary embodiment of the present invention will be described with reference to the following drawings.

FIG. 5 shows two coaxial cables including bare inner conductors facing each other and exposed ends of the shield sleeve. It is a figure which shows the inner conductor connected by using the coupling sleeve. It is a figure which shows the coupling sleeve which provided the intermediate insulation part. It is a figure which shows the shield sleeve of two coaxial cables connected via a shield housing. It is a figure which shows the coaxial cable connector of FIG. 4 which provided the protection shell. It is a sectional view in the longitudinal direction of the coaxial cable connector of FIG. It is a figure which shows the shielded cable which crimped the contact element to the bare conductor end. It is a figure which shows the contact element inserted into the connector housing. It is a figure which shows the connector which cast and wrapped the outside of the connector housing with the intermediate insulation part. It is a figure which shows the end part of the cable which was cast and wrapped in the metal shield housing which has an annular flange. It is a figure which shows the shielded plug connector. It is a figure which shows the plug connector of FIG. 11 surrounded by a protective shell. It is a sectional view in the longitudinal direction of the plug connector of FIG. It is a figure which shows the prepared cable end connected to the plug connector head. It is a figure which shows the end part of the cable which inserted the plug connector head into an injection molding die. It is a figure which shows the cable end part near a plug connector head which the intermediate insulation part was formed around. It is a figure which shows the plug connector head which was inserted into the mold for casting and was formed around the end of a cable. It is a figure which shows the plug connector which was cast and wrapped in the metal shield housing. It is a figure which shows the plug connector of FIG. 18 which provided the protection shell. FIG. 5 is a longitudinal sectional view of a power plug connector including a protective ground connection. It is a longitudinal enlarged sectional view in the rotated cross section of the head of a power plug connector. It is a perspective view of a power plug connector. It is a figure which shows the power plug connector of the angled shape. It is a figure which shows the distributor of a multi-directional terminal block. It is a figure which shows the distributor which was cast and wrapped by the intermediate insulation part. It is a figure which shows the multi-directional terminal block which has a shield housing. FIG. 6 shows a multi-directional terminal block of FIG. 26 having a protective shell. FIG. 27 is a longitudinal sectional view of the multi-directional terminal block of FIG. 27.

1 to 6 show the configuration of the coaxial cable connector. The coaxial cable forms a first shielded wire 1 and a second shielded wire 2. Each wire includes a conductor element 11 or 21, a conductor insulating portion 12 or 22, a shield sleeve 10 or 20, and an insulating jacket 13 or 23. To connect the conductor elements 11 and 21 to each other, a metal coupling sleeve 31 is used that electrically connects the two exposed ends of the conductor elements 11 and 21 to each other. In the space between the conductor insulating portions 12 and 22, an intermediate insulating portion 32 made of heat-resistant insulating plastic is injection-molded so that the conductor insulating portions of the two coaxial cables face each other with substantially the same diameter. The gap between the two exposed insulating jackets 13 and 23 is closed by a shield housing 30 that electrically connects the shield sleeves 10 and 20 to each other. The shield sleeves 10 and 20 are made of, for example, a metal wire mesh so that the wrapping provides good fixation and electrical connection to the shield housing 30. As a result, the electrical contact resistance between the shield sleeves 10 and 20 on the one hand and with the shield housing on the other hand becomes low. Therefore, the shield housing 30 is composed of a metal body that has been cast in situ and produced using a casting tool. FIG. 17 shows the corresponding mold for casting. If necessary, the in-situ cast shield housing 30 is made without a sprue, using hot runner technology, for example as described in German Patent No. 10201209790, which is incorporated herein by reference. It is formed.

In the design according to FIG. 4, the coaxial cable connector can be used as such. Further protective shells 33 are arranged around the shield housing 30 and around the ends of adjacent lines 1 and 2. In this way, the standard design of the connector 3 is established. This completes the shield connection between the two wires 1 and 2.

7 to 13 show the formation of a plug connector for connecting the shielded wire 1 to the contact element 34 of the plug connector. The shielded wire 1, which is a cable, includes one or more conductor elements 11, a conductor insulating portion 12, a shield sleeve 10, and an insulating jacket 13 that completely surrounds the periphery. As can be seen from FIG. 7, the front end portion of the wire 1 is disassembled so that the exposed end portion of the conductor element 11 to which the contact element is crimped protrudes from the conductor insulating portion 12. Further, at the front end portion of the wire 1, the shield sleeve 10 and the insulating jacket 13 are shortened by cutting at the position of 14. Further, to have a shielded annular region 101 axially restricted on both sides, the insulating jacket 13 is cut by cutting to reach the shield sleeve 10 at position 15, and the insulating jacket edge 16 is at the end of the wire. Moving forward towards. Further, the union nut 351 as part of the joint half body 35 has moved over the end of the wire 1 until it reaches the fully insulating casing 13.

The end of the conductor element 11 to which the contact element 34 is crimped enters the bore hole of the insulating connector housing 36 so as to reach the state shown in FIG. As shown, the region 17 remains between the connector housing 36 and the insulating jacket edge 16. As shown in FIG. 8, individual conductor elements 11 having a conductor insulating portion 12 are arranged in the region 17. As shown in FIG. 9, the exposed region 17 is closed by injection molding using an insulating plastic such as Macromelt to form the intermediate insulating portion 32.

Starting from the state shown in FIG. 9, the shield housing 30 is formed by casting a liquid metal around the intermediate insulating portion 32 and the shield sleeve 10 in the annular region 101. The shield housing 30 thus cast in place also partially extends around the insulating connector housing 36, thus forming an annular flange 301. At this point, as shown in FIG. 11, the captured union nut 351 can be moved forward across the shield housing 30 until engaged with the annular flange 301. This is the usable state of the plug connector. When the protective shell 33 is injection molded over the shield housing 30 to obtain a generally commercially available shape, the connector will have the appearance shown in FIGS. 12 and 13.

Further manufacturing of the plug connector 4 will be described with reference to FIGS. 14 to 19. First, the head of the plug connector 4 is connected to the end of the conductor element 11 of the wire 1. For this purpose, the conductor element 11 and the shield sleeve 10 are exposed in the shield annular portion 101, as described with reference to FIG.

The head of the plug connector 4 has a union nut 451 that is a part of a joint half body that cooperates with a fitting plug connector (not shown) to connect the plug connector 4 in a paired manner to the fitting plug connector. The front end of the electrically insulated connector housing 46 covered by the union nut 451 is visible. In the housing 46, a contact element connected to the exposed end of the conductor element 11 is arranged. The head of the plug connector 4 also includes a metal connector 41 that projects at the rear end of the plug connector head and extends forward around the electrically insulated connector housing to ensure a shielding effect when coupled to the mating plug connector. Including.

FIG. 15 shows an open injection molding tool 5 having a cavity that accepts the combination of the head of the plug connector 4 and the wire 1. The metal connecting part 41 has a first seal ring portion 411 that limits the casting cavity 50 in cooperation with the insulating jacket edge 16. An injection molding groove 51 is connected to the casting cavity 50, and an electrically insulating plastic is injected through the groove to cover the conductor element 11. After cooling, the intermediate insulating portion 32 as shown in FIG. 16 is formed.

The unfinished plug connector shown in FIG. 16 is inserted into the cavity of the tool 6 (FIG. 17) into which metal is poured, limiting the casting cavity 60 between the insulating jacket 13 of wire 1 and the second seal ring portion 412. .. Casting grooves 61 and 62 are connected in the casting cavity 60. Liquid metals of metal alloys such as tin solder flow through these grooves. After cooling, the solidified metal alloy forms the shield housing 30. The shield housing 30 surrounds the intermediate insulating portion 32, the insulating jacket edge portion 16, and the shield sleeve 10 in the shield annular region 101. Eliminating any overflows that may occur during the molding process casts a usable plug connector as shown in FIG. However, commercially available plug connectors also have a protective shell 33 around the shield housing 30, as shown in FIGS. 19 and 20.

In order to manufacture such a commercially available plug connector, a usable plug is provided so that the injection tool seals the seal ring portion 412 and the unaffected area of the insulating jacket 13 on the opposite side of the shield housing. Insert the connector into the casting cavity of an additional injection molding tool (not shown). Then, the seal ring portion 412 of the plug connector of FIG. 18 and the unaffected region of the insulating jacket 13 are cast with insulating plastic to form a protective shell 33 surrounding the shield housing 30, whereby FIG. 19 Form a commercially available plug connector shown in.

The work described can be done completely automatically. High-speed production is possible by breaking down the process into individual steps and performing these steps along an assembly line that can also be designed as a circular table. This makes it possible to produce thick wall products with a shorter overall cycle time than when producing plug connectors in a single molding cycle. When insert molding with insulating plastic and casting with liquid metal are performed simultaneously for three consecutive plug connectors, the cycle time per unit plug connector is determined by the longest cycle time in the production process. The cycle time of metal casting is very short.

20 and 21 show a longitudinal cross section of a power plug connector having a protective ground connection (PE connection) of the shield housing 30. As can be seen from these figures, the blank end 110 of the conductor element 11 is mechanically connected to the contact element 44 and also electrically, for example, by soldering, squeezing or crimping. The head of the plug connector 4 has an electrically insulated connector housing 46 having an axial bore hole into which the front end of the contact element 44 is inserted. A tubular metal connecting part 41 extends around the connector housing 46 and engages with the threaded joint 420 to hold a metal half shell 42 that forms part of the joint half 45 of the plug connector 4. A protruding portion 413 is provided. For example, the two half shells 42 are held by the pressing force of the metal connector 41 and the insulating connector housing 46 by coloring. The metal connector 41 and the half shell 42 form an outer shield housing ( shield housing) 40 around the associated connector 4. The shield housing 40 has a rear annular region 401 that is firmly connected to the shield housing 30 by in-situ casting of the shield housing 30.

The power plug connectors shown in FIGS. 20 and 21 are manufactured in the same manner as those described with reference to FIGS. 14 to 19. At the end of the wire 1, a shield annular region 101 that exposes the shield sleeve 10 is provided. In the head of the plug connector 4, a metal connecting component 41 forming a shield over the entire plug connector head can be found together with the half shell 42. The shield of the plug connector 4 is provided by a shield housing 30 manufactured by in-situ casting as described with reference to FIGS. 14-19.

The contact element 440 (FIG. 20) guides the protective ground (PE) and is connected to the in-situ cast shield housing 30 together with the casting branch 303. In this example, the intermediate insulation portion 32 is made of an electrically insulating and low thermal conductive material so as to protect the conductor element 11 from the heat of the molten metal during the manufacture of the shielded housing 30 by casting.

In FIGS. 22 and 23, the interior is constructed similar to the plug connector shown in FIGS. 20 and 21, but the intermediate insulation 32 is made of an electrically insulating and highly thermally conductive material and is therefore in operation. Power plug connector generated Shows a power plug connector that dissipates waste heat better. With the filled plastic, a thermal conductivity value close to 0.2 W / mK to 10 W / mK and a good electrical insulation value can be achieved. On the other hand, the intermediate insulating portion 32 can also be composed of a ready-made ceramic component capable of having a higher thermal conductivity value. Inside the shield sleeve 30, there are also cooling fins 302 that improve heat dissipation from the inside of the power plug connector.

Using the example of the power plug connector of FIG. 23, it is shown that such a power plug connector can be formed in the form of an angled plug connector. However, this also applies to other explanatory designs. Basically, all that is needed is an injection molding tool or casting tool that fits the square shape of the casting cavity.

The data plug connector is also formed in the same manner, and in this case, since less heat needs to be dissipated during the work, a plastic having a low thermal conductivity can be used for the intermediate insulating portion 32. Instead, there is the advantage that the conductor element 11 is better protected from the effects of heat when casting the shield housing 30 in place.

24 to 28 show a shielded multi-directional terminal block constituting a connector for connecting a plurality of shield plug connectors 7 to each other. The connection of the individual plug connectors 7 is made via the distributor 8. The distributor 8 includes two conductor substrates 81 and 82 having a distributor between the connection points 83, 84 and 85. The connection points 85 are connected to each other via the cross connection portion 86.

The plug connector 7 includes a metal connector that forms the outer shield housing ( shield housing) 70 (FIG. 28) and serves as a coupling component with the complementary mating plug connector. Inside the shield housing 70, an electrically insulated connector housing 76 that holds the contact element 74 is attached. The contact element 74 has an extension that is connected to the distributor 8 at the associated connection point 83 or 84 to form the conductor element 71. Starting from the state of FIG. 24, the intermediate insulating portion 32 is injection-molded around the conductor element 71 and the distributor 8 so as to reach the state shown in FIG. After that, a shield housing 30 (FIG. 26) that meshes with the shield housing 70 (FIG. 28) of the plug connector 7 is cast around the intermediate insulating portion 32 manufactured as an in-situ cast metal body, and thus the component 70, The contact resistance between 30 is extremely low. The shield housing 30 surrounds the intermediate insulation 32 without gaps and thus also provides a strong shield for the entire connector in the area of the distributor 8.

A protective shell 33 is then placed around the shield housing 30 to make this connector look like other commercially available connectors. FIG. 27 shows the completed plug connector.

The connector of FIG. 27, formed as a multi-directional terminal block, can also be modified to include one or more shielded wires in which the plug connector 7 is completely absent. In other words, one or more or all or all of the plug connectors 7 can be replaced with directly connected shielded wires 1 or 2. In this case, the conductor elements 11 and 21 of the respective lines are connected to the distributor 8 in the form of the conductor element 71. After that, the intermediate insulating portion 32 is manufactured by injection molding, and the intermediate insulating portion 32 is cast and wrapped in a metal shield housing 30, thereby electrically connecting the connecting lines 1 and 2 to the shield sleeves 10 and 20. Establish. Then, if necessary, the protective shell 33 is attached.

In the present invention, various low melting point metals and metal alloys, specifically metal solders, can be used. All lead-containing tin solders, all lead-free tin solders, and Sn-Bi solders and silver solders having a melting point of around 130 ° C. are also options. In particular, when the connection is made of tin solder and thus fused with the shield housing 30, a tin-plated member is used as the shield sleeve 10 of the relevant wire or the connector 41 of the connector thus formed. It is possible to support the connection with the shield housing 30. It is also conceivable to nickel-plat the target parts. On the other hand, these parts can also be made of blank stainless steel. The shield sleeve can also be formed as a shield braid made of copper wire.

To stabilize the connection between one connecting part 41 and the other shield housing 30, or between the shield sleeve 10 and the shield housing 30, thin fins and thin shields that get very hot with the metal encapsulation, respectively. If the wires are present and therefore these parts are tinned, it is advantageous that the surfaces of these thin parts are locally fused, resulting in a firm soldering. This results in a particularly low electrical contact resistance.

During the test run, the plug connectors according to the invention showed contact resistance in the milliohm range. This very low contact resistance did not change even after significant temperature changes.

A further outstanding feature of the connector according to the present invention is the formation of a shield housing 30 which is a completely self-contained unit except for the supply line or the axial opening which accommodates the plug connector. At these openings, the shield of each connecting wire or plug connector head is connected to achieve a complete shield with a 360 ° spatial angle. Thus, in other words, the shield housing 30 is preferably radial perfect in the area of the wire connection and closed without gaps. Thus, specifically, the shield housing 30 forms a closed metal sleeve along the entire perimeter of the shield connection.

Further Possible Modifications The intermediate insulation 32 serves to protect and / or insulate the conductor element (the core in the case of a cable or the rear end of the contact element in the case of a plug connector), casting the conductor element with insulating plastic. It can also be manufactured by methods other than wrapping. During the manufacture of the shield housing 30, sealants, shrink tubing, plastic housings and adhesives, or off-the-shelf components can be used to protect the conductor elements from liquid metal.

In some embodiments of the intermediate insulation 32, the shield sleeve 10 projects beyond the cutting region 14 to electrically connect the shield housing 30 at the protruding end of the shield sleeve 10 by casting with liquid metal. Can have the potential.

The intermediate insulating portion 32 can also be manufactured by using a low pressure method so as to allow direct sealing of the conductor element 11 or the shield sleeve 10.

The protective shell 33 does not necessarily have to be manufactured by wrapping in plastic. Off-the-shelf parts such as grommets can also be used as the protective shell 33.

Those skilled in the art need to understand the embodiments described herein as an example, and the present invention is not limited to these embodiments, and a plurality of embodiments without departing from the scope of protection of the claims. It will be clear that it can be changed in the form of. Moreover, features individually define the main parts of the invention, regardless of where they are disclosed in the specification, claims, figures or otherwise, even if described with other features. It will be clear.

1 First shielded wire 4 Plug connector 10 Shield sleeve 11 Conductor element 30 Shield housing 32 Intermediate insulation 40 Shield housing 41 Connection parts 42 Half shell 46 Connector housing 101 Shielded annular region 303 Casting branch 401 An annular region 440 Contact element

Claims (16)

A shielded electrical connector that connects or distributes shielded wires or plug connectors to each other.
With one or more conductor elements (11, 21, 71) belonging to at least one shielded wire (1, 2) or at least one shielded electrical plug connector (4, 7).
With one or more shielded sleeves (10, 20) or shielded housings (40, 70) belonging to at least one shielded wire (1, 2) or at least one shielded electrical plug connector (4, 7).
A plurality of shield sleeves (10, 20) are connected to each other, or at least one shield sleeve (10) is connected to at least one shield housing (40), or a plurality of shield housings (70) are connected to each other, or A shield housing (30) forming a part of the shield housing is provided.
The shield housing (30) is composed of a cast metal body on an annular region (101, 201, 401, 701) of one or more shield sleeves (10, 20) or one or more shield housings (40, 70). And formed a fixing means with low electrical contact resistance, resulting in a complete shield of said shielded electrical connector.
The shield housing (30) is a shielded electric connector made of a low melting point metal or a low melting point metal alloy. The shielded electrical connector according to claim 1, wherein the low melting point metal alloy is tin solder. Claim that one of the conductor elements ( 11, 21, 71 ) is on a protective ground (PE) and the shielding housing (40) is electrically connected to the protective ground (PE). The shielded electrical connector according to 1 or 2. A shielded electrical connector that connects or distributes shielded wires or plug connectors to each other.
With one or more conductor elements (11, 21, 71) belonging to at least one shielded wire (1, 2) or at least one shielded electrical plug connector (4, 7).
With one or more shielded sleeves (10, 20) or shielded housings (40, 70) belonging to at least one shielded wire (1, 2) or at least one shielded electrical plug connector (4, 7).
A plurality of shield sleeves (10, 20) are connected to each other, or at least one shield sleeve (10) is connected to at least one shield housing (40), or a plurality of shield housings (70) are connected to each other, or A shield housing (30) forming a part of the shield housing is provided.
The shield housing (30) is composed of a cast metal body on an annular region (101, 201, 401, 701) of one or more shield sleeves (10, 20) or one or more shield housings (40, 70). And formed a fixing means with low electrical contact resistance, resulting in a complete shield of said shielded electrical connector.
One of the conductor elements ( 11, 21, 71 ) is present on the protective ground (PE), and the shield housing (40) is electrically connected to the protective ground (PE). Shielded electrical connector. The shield housing (30) covers the intermediate insulating portion (32) at least partially, and the intermediate insulating portion (32) is used for the conductor elements (11, 21, 71) during the casting process of the shield housing (30). The shielded electrical connector according to any one of claims 1 to 4, which is formed of a heat-resistant electrical insulating material configured to protect the). Formed as the shielded electrical plug connector (4) having a shielding housing (40) and contact elements (34, 44) for connecting to the mating plug connector, the contact element (34) of the shielded electrical plug connector (4). , 44) are provided with electrically insulated connector housings (36, 46) that form a conductor element of the shielded electric plug connector (4) and hold the contact element inside, and the shielded electric plug connector (4) is provided with an electrically insulated connector housing (36, 46). The shielded electric connector according to any one of claims 1 to 5, wherein a joint half body (45) effective as an electric shield connecting portion to the fitted plug connector is formed. The shielding housing (40) is fixed on the electrically insulated connector housings ( 36, 46) by using a sleeve ring (43) to form a part of the joint half body (45). The shielded electrical connector according to claim 6, further comprising a 41) and a metal half shell (42). The shield electrical plug connector (4), the data plug connector is formed as an intermediate insulating portion including a low thermal conductivity electrically insulating material having a plurality of conductor element (11) surrounded by (32), according to claim 6 Or the shielded electrical connector according to 7 . The shielded electrical plug connector (4) is formed as a power plug connector and has a plurality of conductor elements surrounded by an intermediate insulating portion (32), and the intermediate insulating portion (32) is electrically insulated with low thermal conductivity. The shielded electrical connector according to claim 6 or 7 , wherein the shielded housing (30) comprises a material and has cooling fins (302). Formed as a multi-directional terminal block for one or more shielded wires and / or one or more shielded electrical plug connectors (7).
Distributor having multiple connection points (83,84) for said conductor elements (11,21,71) belonging to either one or more shielded wires or one or more of said shielded electrical plug connectors (7). (8) and
The distributor (8) is provided with an intermediate insulating portion (32) that surrounds the conductor elements (11, 21, 71) adjacent to the distributor (8).
The shielded housing (30) has an intermediate insulating portion in either an annular region of the shielded sleeve of the shielded wire and / or an edge region (701) of the shielded housing (70) of the shielded electric plug connector (7). The shielded electrical connector according to claim 6 or 7 , which surrounds (32). The shielded electrical connector according to any one of claims 1 to 10, wherein the shield housing (30) is surrounded by an electrically insulated protective shell (33). The method for manufacturing a shielded electrical connector according to any one of claims 1 to 11.
a) Steps to connect the exposed ends of the conductor elements (11, 21) to each other,
b) A step of optionally applying an intermediate insulation (32) on the exposed ends of the conductor elements (11, 21) connected to each other.
c) Cast one or more shield sleeves (10, 20) and / or one or more shield housings (40, 70) that were once exposed, and intermediate insulation (32), if any, with liquid metal. A method of manufacturing a shielded electrical connector, comprising wrapping and forming a shielded housing (30). A shielded electrical connector manufacturing method according to claim 5, wherein the shield electrical connector connects the first shielding line (1) to the second shield wire (2), wherein the manufacturing method,
a) A step of exposing the shielded sleeve (10, 20) and the conductor element (11, 21) at the ends of the first shielded wire and the second shielded wire (1, 2).
b) A step of connecting the exposed ends of the conductor elements (11, 21) to each other, and
c) With the step of applying the intermediate insulation (32) on the exposed ends of the conductor elements (11, 21) connected to each other.
d) A method for manufacturing a shielded electrical connector, which comprises a step of casting the intermediate insulating portion (32) and the exposed shield sleeve with a liquid metal to form a shield housing (30). The method for manufacturing a shielded electric connector formed as the shielded electric plug connector (4) according to claim 6, wherein the shielded electric plug connector (4) uses the conductor element (11) of the shielded wire (1) as described above. It is connected to the contact element of the shielded electric plug connector (4), and the manufacturing method is as follows.
a) A step of exposing the shielded sleeve (10) and the conductor element (11) at the end of the shielded wire (1).
b) A step of applying the contact element (44) to the end of the conductor element (11) and insulating the contact elements from each other using electrically insulated connector housings ( 36, 46).
c) In the step of applying the intermediate insulation (32) on the conductor element (11) with exposed ends,
d) A method for manufacturing a shielded electrical connector, which comprises a step of casting the intermediate insulating portion (32) and the exposed shield sleeve (10) with a liquid metal to form a shield housing (30). The method for manufacturing a shielded electric connector formed as a multi-directional terminal block according to claim 10, wherein the shielded electric connector is one or more shielded wires and / or one or more shielded electric plug connectors (7). Are connected to each other, and the manufacturing method is
a) One or more exposed shielded sleeves and conductor elements at the ends of one or more shielded wires to be connected and / or each having a respective shielding housing (70) and each plug conductor element (71). Steps to prepare multiple shielded electrical plug connectors (7),
b) The step of connecting the conductor element or the plug conductor element (71) to the distributor (8), and
c) A step of applying the intermediate insulation (32) on the exposed conductor element or on the exposed plug conductor element and around the distributor (8).
d) When connecting the shield wire, the intermediate insulating portion (32) and the exposed shield sleeve are cast and wrapped with liquid metal, and / or when connecting the shield electric plug connector (7), the shield housing. A method for manufacturing a shielded electrical connector, which comprises a step of casting a liquid metal on the edge region (701) of (70) to form a shielded housing (30). As far as the shielded wires (1, 2) are concerned, one or more shields of the shielded housing (30) and the shielded wires (1, 2) by partially fusing the metal in the target shielded sleeves (10, 20). The method for manufacturing a shielded electric connector according to any one of claims 12 to 15, wherein each soldering connection with the sleeve (10, 20) is made.